Method of printing gaming table fabric

ABSTRACT

A method of printing a gaming table fabric includes the step of obtaining a piece of fabric, the fabric comprising a fiber material which expands when heated. A wet gel ink is applied to one or more portions of a top of the fabric. The gel ink is allowed to dry. The gel ink is then heated, causing the ink to sublimate and travel from the top of the fabric towards a bottom of the fabric.

FIELD OF THE INVENTION

[0001] The present invention relates to a method of printing a fabric and more particularly, to a method of printing a fabric material for use as a gaming table covering.

BACKGROUND OF THE INVENTION

[0002] Gaming tables, such as Blackjack and Craps tables, are generally covered by a fabric material. The fabric material serves as a desirable playing surface. The fabric is pleasant to the touch, and provides sufficient friction to stop dealt cards and chips from freely sliding over the table. The fabric also makes cards easier to pick up, as the cards do not stick or adhere to the fabric. Also, the fabric provides a cushion for thrown dice and similar objects.

[0003] As is also known, the fabric of these gaming tables is generally printed with text and/or graphics. The printing comprise text such as instructions or rules for the game which is played at the gaming table. The printing may comprise graphics defining player or bet locations and/or aesthetically pleasing geometric shapes and patterns. In essence, the fabric serves as a “game board” for the game played at the gaming table.

[0004] In recent years, casinos and others offering games at gaming tables have sought improved gaming table fabrics. Traditionally, gaming table fabric has comprised a thick wool fabric having a green background color. This green fabric is printed with the desired text and graphics. Because of the green background color, it has traditionally been difficult to print the fabric in many colors. For example, it is difficult to print text or images in white when the fabric is green.

[0005] Casinos have, however, sought to make their gaming tables more attractive. Casinos have sought to present gaming table fabrics and associated printing in brighter, more exciting colors. Casinos have also sought to introduce more intricate designs to the fabrics.

[0006] At the same time, casinos desire that the gaming table fabrics have a long life. One significant problem, as detailed below, is that the printing on some gaming table fabrics often wears very quickly. This makes the text or graphics hard to read, or simply makes the fabric prematurely appear old and worn, and thus requires replacement by the casino.

[0007] Unfortunately, the present methods of printing gaming table fabrics suffer from a variety of problems which generally prevent the achievement of these goals.

[0008] The most common method of printing gaming table fabric is to apply a wet gel dye mixture to a wool or nylon. Once applied, the wet gel dye is quickly cured in the presence of steam.

[0009] This method has a number of problems. First, as described above, the number of colors of fabric printing are generally limited. If the fabric is a green color, then certain colors of applied gel dye when placed on the green fabric will not appear their true color because of the green fabric background.

[0010] Another problem is that the applied steam causes the wet gel dye to travel through the fabric. As a result, edges of printed areas often become blurred or distorted. This makes the gaming table fabric visually unappealing and thus undesirable and unusable. In some instances, the blurring is so great that the printing is simply unreadable.

[0011] Another problem is that the printing is only located at the surface of the fabric. The fabric itself, when completely dyed green, wears well. However, the later applied printing located at only the surface of the fabric wears quickly. Movement of objects along the surface of the fabric, such as players' hands and cards, wears off the cured gel dye, removing the printing from the fabric.

[0012] Another disadvantage to this method is that it is difficult. A correct amount of dye gel must be applied, and the fabric must be cured in steam at the proper temperature and for the proper time, in order for the process to be effective. For example, the method described in U.S. Pat. No. 5,568,666 requires that the dye gel be applied to only the top surface of the fabric, otherwise the dye may bleed and the fabric becomes very difficult to move. It is difficult at best to ensure that sufficient dye is applied to the fabric to print it, but that not so much dye is applied that the dye travels through the fabric.

[0013] Other methods of printing fabric also suffer from various problems or significant disadvantages. For example, another method of printing involves applying dry or solid dye onto paper. The dye must be applied in the exact configuration or pattern which it is desired that the fabric be printed.

[0014] After the solid dye is applied to the paper, the paper is placed against the top surface of a fabric material. Once aligned, heat is applied to the paper to cause the dye to be applied to the top of the fabric.

[0015] One problem with this method is that it is time intensive and expensive. First, an expensive printer must be obtained. To prevent seams and similar discontinuities which are undesirable, the fabric for a gaming table is a single piece. This fabric piece may be 4-5 feet long and 4-5 feet wide. In order to print a fabric using this method a paper of the same size as the fabric piece and printed with solid dye must be utilized.

[0016] The method also requires that the solid dye be first applied to the paper. This is an extra step in the process. Further, a computer or other controller must be used, as the solid dye must be applied in reverse image. This is because the image reverses when the solid dye on the paper is applied to the fabric.

[0017] The method also requires a special heat press device. The heat press device must be sufficiently large to permit the paper and fabric to be aligned and pressed together while moving through a heating element. Since the dye is adhered to the paper, both pressure and heat are required to ensure the transfer of the solid dye from the paper to the fabric.

[0018] To ensure that the dye is applied properly and fully, the heating time is very long. This is because, in part, the paper must be heated along with the dye. As a result, the total time to print a single large piece of fabric may be 4-6 hours.

[0019] Yet another problem with this method is that the fabric is only printed on the top surface. As a result, the fabric wears quickly and needs to be replaced often.

[0020] A quick, inexpensive method of effectively printing gaming table fabric with various graphics and text, in a variety of colors, and having a high durability, is desired.

SUMMARY OF THE INVENTION

[0021] The present invention is a method of printing a fabric, especially a fabric of the type used to cover a gaming table.

[0022] In one embodiment of the invention, the method includes the step of obtaining a piece of fabric, the fabric comprising a fiber material which expands when heated, the fabric having a top and a bottom. Gel ink is applied to one or more portions of the top of the fabric. Next, the gel ink applied to the fabric is dried. Lastly, the dried gel ink is heated, causing the ink to sublimate and travel from the top of the fabric towards the bottom of the fabric.

[0023] The fabric preferably comprises a polyester material. The gel ink preferably comprises a dispersion or sublimating dye.

[0024] In one embodiment, the step of applying the gel ink comprises the step of locating a printing screen over the top of the fabric and applying the gel ink to the fabric through one or more locations of the printing screen. In one embodiment, the printing screen is arranged as a gaming table template.

[0025] The applied, wet gel ink may be dried at room conditions. Preferably, however the wet gel ink is exposed to a moving air source to expedite drying and prevent running of the applied ink.

[0026] In one embodiment, a dry heat is applied to the dried gel ink, causing the ink to sublimate and the fibrous material comprising the fabric to expand. Preferably, the dried ink and fabric are heated to between 200 and 475 degrees F. Heat may be applied using a heated roller or other means.

[0027] Further objects, features, and advantages of the present invention over the prior art will become apparent from the detailed description of the drawings which follows, when considered with the attached figures.

DESCRIPTION OF THE DRAWINGS

[0028]FIG. 1(a) illustrates a first step of a method of printing a gaming table fabric in accordance with an embodiment of the invention, the step comprising providing the fabric and a dye screen;

[0029]FIG. 1(b) illustrates a second step of a method in accordance with an embodiment of the invention, the step comprising applying a gel dye to the fabric, such as through the dye screen to create a desired text and graphics;

[0030]FIG. 1(c) illustrates the fabric with the gel dye applied thereto in a desired pattern;

[0031]FIG. 1(d) illustrates a third step of a method in accordance with an embodiment of the invention, the step comprising drying the applied gel dye;

[0032]FIG. 1(e) illustrates a fourth step of a method in accordance with an embodiment of the invention, the step comprising heating the applied gel dye;

[0033]FIG. 2(a) is an enlarged cross-sectional view of a portion of a gaming table fabric after a gel dye has been applied to a top surface thereof;

[0034]FIG. 2(b) illustrates the portion of gaming table fabric illustrated in FIG. 2(a) after heat has been applied thereto; and

[0035]FIG. 3 illustrates a method in accordance with the invention in flowchart form.

DETAILED DESCRIPTION OF THE INVENTION

[0036] The invention is a method of printing a gaming table fabric. In the following description, numerous specific details are set forth in order to provide a more thorough description of the present invention. It will be apparent, however, to one skilled in the art, that the present invention may be practiced without these specific details. In other instances, well-known features have not been described in detail so as not to obscure the invention.

[0037] In general, the invention comprises a method of printing a fabric piece which is preferably used as a gaming table covering. In one embodiment, the method generally comprises the steps of applying a wet gel dye or ink to a top surface of the fabric, drying the gel or ink, and then heating the dried dye to release it into the fiber of the fabric.

[0038] One embodiment of the invention will be described with reference to FIGS. 1(a)-1(e). In a first step, as illustrated in FIG. 1(a), a piece of fabric 20 is obtained. In a preferred embodiment, the fabric 20 is polyester or other fibrous material which, when exposed to heat, has properties causing the fibers to expand. In one embodiment, the fabric 20 is a polyester weave, such as that available from Milliken & Co. of Spartanburg, S.C., Guilford Mills of Greensboro, N.C., Fab Industries, Inc. of New York, N.Y., or Fisher Textiles of Ironton, Pa.

[0039] The fabric 20 may be of other types. For example, the fabric 20 may be other synthetic materials, including nylon. The fabric 20 may have a variety of fiber weaves. Other characteristics of the fabric, such as the thickness, may vary.

[0040] The fabric 20 may be of a variety of colors. In one embodiment, the fabric 20 is white. If the fabric 20 is of a different color, it may be woven or constructed from dyed fiber or strands, or it may be dyed after construction.

[0041] The fabric 20 piece is preferably sufficiently large to cover the entire gaming table surface at which the fabric 20 is to be used. The fabric 20 may be cut before or after printing. In the embodiment illustrated in FIG. 1(a), the fabric 20 is illustrated as having been constructed or cut to size. In the embodiment illustrated, the fabric 20 piece has a shape and size for covering a “Blackjack” or “21” table. It will be appreciated that the fabric 20 piece may have a variety of shapes and sizes. For example, the fabric 20 piece may be generally rectangular or circular.

[0042] As described below, in a following step a gel dye is applied to the fabric 20. As such, in one embodiment of the invention, as illustrated in FIG. 1(a), a print screen 22 may be obtained for use in selectively applying the dye gel.

[0043] The print screen 22 may have a variety of configurations, and such screens are well known to those of ordinary skill in the art. In general, the screen 22 comprises a surface or body which in one or more locations prevents the passage of dye gel therethrough from a top to a bottom surface thereof. The screen 22 also defines printing areas 24 where dye gel is permitted to pass through the surface or body from the top to the bottom surface.

[0044] As illustrated in FIG. 1(b), in another step of a method of the invention, a dye or ink 26 is applied to the fabric 20. In a preferred embodiment of the invention, the dye or ink 26 which is applied to the fabric 20 is a gel dye. This dye 26 is a viscous fluid, and is thus wet or has a liquid or semi-liquid form. Preferably, the dye 26 is also of a type which when exposed to heat readily turns into a gas and disperses.

[0045] One such dye 26 is known as a dispersion dye or a sublimation dye. Such dyes 26 are available from Bezjian Dye Chem, Inc. of Glendale, Calif., Keystone of Spartanburg, S.C., Yorkshire Patchem of Greenville, S.C., and Ciba Geigy of Greensboro, N.C. The dye 26 may have a variety of colors, such as terasil blue, pink, violet, yellow and red, from Ciba Giegy. It will be appreciated that the particular choice of dye color is primarily dependent upon the desired end-product. In the event the selected fabric 20 is white, it will be appreciated that nearly any color dye 26 may be applied to the fabric and be visible.

[0046] In one embodiment, a thickener is used with the dye 26. In some instances, the dye 26 may initially be in dry form. The thickener 26 is a gel or liquid which may be mixed with the dry dye 26 to make it wet or liquid for application. In the case of liquid dyes 26, addition of the thickener 26 increases the viscosity of the dye 26. It is preferred that the wet dye 26 have a high viscosity because when applied to the fabric 20, it then does not seep or leach from the applied areas to other areas of the fabric 20, thus reducing any blurring of the applied dye 26. Such thickeners are sold under the names Alcoprint, Serviprint, and Diaprint available from Ciba Geigy.

[0047] In a preferred embodiment, the dye or ink 26 is applied using the screen 22. As illustrated, a bottom surface of the screen 22 is placed against a first or top surface of the fabric 20. The dye 26 is then applied to the top of the screen 22. In the desired areas, the dye 26 passes through the screen 22 onto the fabric 20.

[0048] The dye or ink 26 may be applied in other manners. For example, the dye or ink 26 could be applied with a mechanical device, such as a pressurized sprayer or other applicator. The dye or ink 26 may also be applied freehand, such as using an applicator such as a brush.

[0049] It will be appreciated that the dye 26 is preferably applied to create the desired text or graphics or other printing. As illustrated, for example, the dye 26 has been applied to create the text “21” plus graphics comprising bet or wager locations 28 (see FIG. 1(c)) and card locations 30. A variety of patterns, text and other graphics may be created by applying the dye 26 to the fabric.

[0050]FIG. 1(c) illustrates the fabric 20 after the dye 26 has been applied to the top surface thereof as described above. As illustrated, the dye 26 has been applied to the fabric 20 to create desired text and graphics on the fabric.

[0051] In another step in accordance with a method of the invention, the dye or ink 26 is dried. In one embodiment, the fabric 20 is simply allowed to set dry. For example, the fabric 20 may be left in a room at room temperature for 12-24 hours (depending on temperature and humidity and other environmental factors) or as long as is necessary for the dye or ink 26 to completely dry.

[0052] In other embodiments, the fabric 20 and associated dye or ink 26 may be dried in other ways. For example, as illustrated in FIG. 1(d), the fabric 20 may be exposed to a source of flowing air 32, such as from a dryer 34. The fabric 20 may be passed under a source of moving air. The air may be heated, although it is desired that at the time the dye is being dried the fabric 20 not be exposed to heat in an amount greater than necessary to activate the dye in a manner as described below.

[0053] Referring to FIG. 2(a), at this time, dye or ink 26 is applied or adheres to only a portion of the fibers or other material forming the fabric 20. FIG. 2(a) illustrates a portion of the fabric 20 after dye or ink 26 has been applied thereto, as in FIGS. 1(c) or (d). As illustrated, the fabric 20 comprises a plurality of fibers 36. The fibers 36 generally define a top 38 or first surface or area and a bottom 40 or opposing second surface or area of the fabric 20. As indicated above, dye or ink 26 is applied to the top 38 of the fabric 20. After application, including drying, the dye or ink 26 is only associated with the fibers 36 near the top 38 of the fabric 20.

[0054] Referring now to FIG. 1(e), in another step of a method of the invention, heat is applied to the dried dye or ink 26. Sufficient heat is applied to the dye or ink 26 to activate the dye or ink 26. This step comprises causing the dye or ink 26 to sublimate (change from a solid state directly to a gaseous state). The gaseous dye or ink 28 is driven through the fibers forming the fabric 20.

[0055] Sufficient energy is imparted to the dye or ink to raise the temperature of the dye or ink. This energy may be imparted in a number of ways via conduction, convection, and/or radiation. For example, a heated roller may be used. To avoid contact with the dye which may adhere to the roller, the energy may be imparted by convention, such as by using heated air, or by radiation, such as with a lamp or the like.

[0056]FIG. 2(b) illustrates a portion of the fabric 20 after step 1(e). As illustrated, the dye or ink 26 has sublimated, traveling through the fibers 36 of the fabric 20 from the top 38 to the bottom 40.

[0057] In one embodiment, the heat or energy which is applied is a dry heat. By “dry heat” it is meant that energy is applied in an environment of low water mass. For example, dry heat may be applied using a hot air blower. In such an embodiment, sufficient energy is preferably transferred to the fabric 20 and dye 26 to raise their temperature to between 200 degrees F. and 475 degrees F. In general, the higher the temperature to which the dye is raised, the brighter the resulting color of the dyed fabric.

[0058] In another embodiment, the heat or energy which is applied is a wet heat. By “wet heat” it is meant that energy is applied in an environment of high water mass. For example, a steam press may be used to impart the heat to the fabric 20 and dye 26. In this embodiment, the temperature of the fabric 20 and dye 26 are preferably raised to 200 degrees F. to 280 degrees F.

[0059] In one embodiment, when applying dry heat at 470 degrees F., the total time heat is required to be applied is approximately 40 seconds to 1.5 minutes. In the case of wet heat, such as steam at 210-260 degrees F., the time is 8 to 12 minutes. It will be appreciated that the total time heat must be applied in order to reach the desired temperature depends upon a number of factors, such as the thickness of the fabric and the amount of energy transferred by the heat generating device. For example, the time for heating steam may be greatly reduced if the temperature of the steam is much higher.

[0060] In a preferred embodiment of the invention, as described above, the fabric 20 is preferably of a type having fibers which, when exposed to heat, expand. In this manner, the heat used to activate the dye or ink 26 also causes the fibers 36 of the fabric 20 to expand or open. The expansion of the fibers provides air passages through which the activated gaseous dye or ink 26 freely travels. This contributes to the sublimation of the dye or ink 26 from the top 38 to the bottom 40 of the fabric 20.

[0061] Preferably, heating of the fabric 20 to the above stated temperatures using dry and wet heat causes the fibers 36 of the fabric 20 to expand as well as the dye to travel or sublimate. Once again, the total time to heat is preferably selected so that the applied dye 26 sublimates and the fabric 20 is caused to expand. It has been found that both events occur in the above-stated ranges. However, other dyes and/or fabrics may behave differently, requiring heating to higher or lower temperatures.

[0062]FIG. 3 is a flowchart illustrating a general flow of a method of the invention. In a first step S1, a fabric to be printed is obtained. As indicated above, the fabric may be of a variety of types. The fabric is preferably white, but may be one or more colors, such as from dying. The fabric is preferably of the type which is constructed from material or fibers which expand when subjected to heat. As indicated above, this step may include the step of cutting the fabric to a particular configuration.

[0063] In a step S2, ink or dye is applied to the fabric. The ink or dye is preferably a material which sublimates which exposed to heat. As indicated above, the ink or dye is preferably applied to a surface of the fabric, such as a top of the fabric. The ink or dye may be applied manually, including by use of a screen, or in an automated fashion.

[0064] In a step S3, the ink or dye is allowed to dry. This step may comprise simply leaving the fabric static for a period of time sufficient (given conditions such as temperature and humidity) to cause the ink or dye to dry. The step may also or instead comprise actively drying the ink or dye, such as by moving an air stream over the ink or dye.

[0065] In a step S4, heat is applied to the ink or dye which has been applied to the fabric. Various means may be utilized to subject the ink or dye to heat, such as heat presses, ovens and the like.

[0066] Another aspect of the invention is a fabric which is printed in accordance with a method of the invention. Preferably, the fabric is a gaming fabric used to cover a gaming table. The fabric is printed with game play information in accordance with the method.

[0067] The invention has numerous advantages over the prior art. Most importantly, the method of the invention is a simple and efficient manner of printing fabric, the printing being durable.

[0068] As opposed to methods such as that where a paper is reverse printed and then applied to fabric to transfer the dye, the method of the invention is simplified because the ink or dye is directly applied to the fabric. Thus, the method of the invention eliminates several time consuming, complex steps as compared to other methods of the invention.

[0069] Because gel or semi-liquid ink or dye is applied, a greater volume of ink or dye can be applied to the fabric, as opposed to the method where the ink or dye is printed to paper and then transferred to the fabric. Further, the gel dye or ink penetrates into the fabric, ensuring better depth of printing, as detailed below.

[0070] Because the ink or dye is applied directly to the fabric, large fabrics may be printed quickly and without expensive machinery. No large paper printers are required. Instead, the ink or dye may be applied by hand, such as quickly through an overlying printing screen.

[0071] Once the fabric is printed with ink or dye, it may be permitted to dry without the need for any complex processing. For example, the printed fabric may simply be left on a drying table overnight.

[0072] Most importantly, the method results in printing which penetrates deep into the fabric. In most instances, the penetration is so great that the printing penetrates the entire depth of the fabric from the original printed side to the back or bottom side. This is advantageous, since wear of the fabric from the top side will not wear off the printing. To the contrary, the printing stays vibrant and visible regardless of the wear of the fabric because the printing extends through the depth of the fabric.

[0073] It will be understood that the above described arrangements of apparatus and the method therefrom are merely illustrative of applications of the principles of this invention and that many other embodiments and modifications may be made without departing from the spirit and scope of the invention as defined in the claims. 

I claim:
 1. A method of printing a gaming table fabric comprising: obtaining a piece of fabric, said fabric having a top and a bottom; applying a gel ink to one or more portions of said top of said fabric; drying said gel ink applied to said fabric; and heating said dried ink, causing said ink to sublimate and travel from said top of said fabric towards said bottom of said fabric.
 2. The method in accordance with claim 1 wherein said piece of fabric comprises a polyester material.
 3. The method in accordance with claim 1 wherein said step of heating comprises heating said ink to between 200 and 475 degrees F.
 4. The method in accordance with claim 1 wherein said gel ink comprises a dispersion dye.
 5. The method in accordance with claim 1 wherein said step of drying said gel ink comprises exposing said gel ink to a moving air source.
 6. The method in accordance with claim 1 wherein said step of drying said gel ink comprises exposing said gel ink to room conditions over time.
 7. The method in accordance with claim 1 wherein said step of heating said dried ink comprises applying a heated roller to said top of said fabric.
 8. The method in accordance with claim 1 wherein said step of applying said gel ink comprises the step of locating a printing screen over said top of said fabric and applying said gel ink to said fabric through one or more locations of said printing screen.
 9. A method of printing a gaming table fabric comprising: obtaining a piece of fabric, said fabric comprising fibrous material defining a first surface and an opposing second surface, said fibrous material of the type which expands when heated; applying wet dye to one or more portions of said first surface of said fabric; drying said wet dye applied to said fabric; and applying heat to said dye and said fabric, causing said dye to sublimate and travel from said first surface of said fabric towards said opposing second surface, and causing fibers comprising said fibrous material to expand, permitting said sublimated dye to travel therethrough.
 10. The method in accordance with claim 9 wherein said step of applying heat comprises applying a dry heat until said fabric and dye reach a temperature between about 200 and 475 degrees F.
 11. The method in accordance with claim 9 including the step of overlying said first surface of said fabric with a printing screen and applying said wet dye to said fabric through one or more portions of said screen.
 12. The method in accordance with claim 9 wherein said fabric comprises polyester. 